Nothern Lights M1276A1 User manual

Brand: Nothern Lights

Model: M1276A1

Category: Engine

Type: User manual

This manual is also suitable for

M1276A2

OM1276

For Models: M1276A1 and M1276A2

OPERATOR’S MANUAL

Marine Generators | Marine Diesel Engines | Land-Based Generators

Diesel engine exhaust and some of its constitu-

ents are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

— CALIFORNIA —

Proposition 65 Warning:

Northern Lights

4420 14th Avenue N.W.

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

the Northern Lights logo are trademarks of

Northern Lights, Inc.

Printed in U.S.A.

PART NO.: M1276 7/13

OM1276 7/13

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

OPERATOR'S MANUAL

OM1276 for Models:

INTRODUCTION ....................................................2

Models Included .................................................2

Model Numbers ..................................................2

Serial Numbers ...................................................2

WARRANTY ..........................................................3

SAFETY RULES ...............................................3 - 7

LOCK OUT / TAG OUT PROCEDURE ..............8

COMPONENT LOCATIONS

M1276 .................................................................9

ENGINE & GENERATOR CONTROL PANELS

Series 3B & 4B .........................................10 - 11

OPERATING PROCEDURES

Before Starting ................................................. 12

Shutdown Procedures ...................................... 12

Break-In Period ................................................ 13

SERVICING SCHEDULE CHARTS .................. 14

SERVICING

Lubrication - General ....................................... 16

Checking Oil .................................................... 16

Oil Changes ..................................................... 16

Changing Oil Filter .......................................... 16

Air Filter .......................................................... 16

Valve Clearances .............................................. 17

Electronic Unit Injector Preload ...................... 18

Fuels - General ................................................. 19

Fuel Filters ............................................... 19 - 20

Bleeding the Fuel System ................................ 21

Crankshaft Vibration Damper ......................... 21

Thermostats ...................................................... 21

Turbocharger .................................................... 22

Turbo Boost ..................................................... 22

Cooling System - General ................................ 22

Engine Coolant Speciﬁ cations ................. 22 - 23

Cooling System Flushing ................................. 24

Heat Exchanger Cleaning ................................ 24

Zinc Electrodes ................................................ 24

Raw Water Pump ............................................. 25

Generator Ends ................................................ 25

Electrical System - General ............................. 25

Booster Batteries .............................................. 25

Battery Care ..................................................... 26

Winterizing / Out-of-Service ........................... 26

TROUBLESHOOTING

Electrical .......................................................... 27

Engine ...................................................... 27 - 30

ON-BOARD SPARE PARTS .............................. 31

WIRING DIAGRAMS

AC Wiring ........................................................ 32

Proprietary Information

This publication is the property of Northern Lights, Inc.

It may not be reproduced in whole or in part without the written permission of Northern Lights, Inc.

Table of Contents

M1276A1 and M1276A2

OM1276 7/13

Servicing of marine engines and generator sets pres-

ents unique problems. In many cases boats cannot be

moved to a repair facility. Marine engines cannot be

compared to the servicing of automobiles, trucks or

even farm equipment. Failures often occur in remote

areas far from competent assistance. Marine engines

are taxed far more severely than auto or truck engines;

therefore, maintenance schedules must be adhered to

more strictly.

Failures begin with minor problems that are overlooked

and become ampliﬁ ed when not corrected during rou-

tine maintenance.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

Introduction

M - Northern Lights marine generator set

Model number

176 mm bore, 6 Cylinder

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

A - Aftercooled

Northern Lights

aftercooled, 1800 or 1500

RPM marine diesel generator set with a John

Deere Powertech engine block and an

electronically controlled fuel system.

1276

Northern Lights

aftercooled, 1800 or 1500

RPM marine generator set with a John Deere

Powertech engine block and an electronically

controlled fuel system, different generator end.

M1276A2

Serial Numbers

When referencing Northern Lights equipment by serial number, please refer only to the number

stamped on the Northern Lights

serial number plate.

M1276A1

Serial Numbers

Model Numbers

OM1276 7/13

A warranty registration certiﬁ cate is supplied

with your set. The extent of coverage is described

in the Limited Warranty Statement. We

recommend that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing

instructions outlined in this manual must be

followed. If further information is needed, please

contact an authorized dealer or the factory.

Warranty

Revised 7-10-13

Safety Rules

NOTICE: Accident reports show that careless use of engines causes a high percentage of accidents.

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

IMPORTANT SAFETY INSTRUCTIONS.

Electromagnetic equipment, including generator sets

and their accessories, can cause bodily harm and

life threatening injuries when improperly installed,

operated or maintained. To prevent accidents be aware

of potential dangers and act safely.

READ AND FOLLOW ALL SAFETY

INSTRUCTIONS IN THIS MANUAL,

PRIOR TO THE INSTALLATION

OF ANY GENERATOR SET OR

ACCESSORY. KEEP THESE

INSTRUCTIONS FOR FUTURE

REFERENCE.

Recognize Safety Symbols and Instructions

In addition to the information found in this section, this

operator’s manual uses three different signal words to

outline potential dangers of a speciﬁ c nature.

Follow All Safety Instructions

Carefully read and understand

all safety messages in this

manual and on your machine’s

safety signs. Keep signs in good

and clean condition. Replace

missing or damaged signs. Be

sure new equipment components and repair parts

include the current safety signs. For replacement signs,

proper placement of safety signs or clariﬁ cation on any

safety issue, consult your Northern Lights dealer or the

factory.

There can be additional safety information contained

on parts and components from outside suppliers

that is not reproduced in this manual. Consult the

suppliers for additional safety information.

Learn how to operate the machine and how to use

the controls properly. Only trained personnel should

operate machines, or work on or around them.

Keep you machine in proper working condition.

UNAUTHORIZED MODIFICATIONS TO THE

MACHINERY MAY IMPAIR ITS FUNCTION

AND SAFETY PARAMETERS.

Prevent Bypass and Accidental Starting

Do not start engine by shorting

across start terminal. Engine will

start if normal circuitry is bypassed,

creating a hazard by runaway

machinery.

Start engine only from operator’s station.

Handle Fuel Safely - Avoid Flames

Diesel is highly ﬂ ammable and should be treated

with care at all times. Do not refuel while smoking

or when near sparks or open ﬂ ame.

ALWAYS STOP ENGINE

BEFORE FUELING

MACHINE. Always ﬁ ll

portable fuel tank outdoors.

Never fuel a hot engine.

DANGER indicates a hazardous situation which, if

not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if

not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation which,

if not avoided, could result in minor or moderate

injury.

OM1276 7/13

Safety Rules (Continued)

Added 1-9-13

Operating equipment requires the full attention of

the operator. Do not use radio or music headphones

while operating machinery.

Practice Safe Maintenance

Understand all service procedures

before starting work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is

in operation.

Keep hands, feet and clothing away from power-

driven equipment. When shutting down an engine,

disengage all power and operator controls. Allow

the engine to cool completely before beginning any

service work.

Securely support any machinery elements that must

be raised for service work with support or lifting

machinery speciﬁ cally intended for that purpose.

Keep all parts in good conditions and properly

installed. Fix damage immediately. Replace any

worn or broken parts. Remove any build up of

grease, oil or debris.

Disconnect battery ground cable (-) before making

any adjustments or service work.

Stay Clear of Rotating Drivelines

Entanglement in rotating drivelines can cause serious

injury or death. Keep shields in place at all times.

Make sure that rotating shields turn freely in pace

with the drivelines.

Do not wear loose ﬁ tting equipment around rotating

drivelines. Stop the engine and make sure that all

moving parts have stopped

before making any adjustments,

connections, or performing

any other type of service to

the engine or other driven

equipment.

Prevent accidental discharge of starting ﬂ uids by

storing all cans in a cool, safe place, away from sparks

or open ﬂ ame. Store with cap securely on container.

Never incinerate or puncture a fuel container.

Prevent ﬁ res by keeping machine clean of accumulated

trash, grease and debris. Always clean any spilled fuel

as swiftly as possible. Do not store oily rags, which

can ignite and burn spontaneously.

Be prepared if a ﬁ re starts. Keep a ﬁ rst aid kit and ﬁ re

extinguisher handy. Keep emergency contact numbers

for ﬁ re department, doctors, ambulance and hospital

near the telephone.

Service Machines Safely

Do not wear a necktie, scarf,

necklace, rings or other

jewelry, or any loose clothing

when working near moving

parts. Tie long hair behind your head. If any of these

items get caught in moving machinery, severe injury or

death could result.

Check for any loose electrical connections or faulty

wiring.

Look completely around engine to make sure that

everything is clear before starting.

Wear Protective Clothing

To prevent catching anything in moving machinery,

always wear close ﬁ tting clothes and safety equipment

appropriate to the job.

Prolonged exposure to loud noise can cause hearing

loss or impairment.

Wear suitable authorized

hearing protection, such

as earmuffs or plugs to

protect against loud noises.

OM1276 7/13

Safety Rules (Continued)

Added 1-9-13

Install all Safety Guards

Direct contact with rotating

fans, belts, pulley and drives

can cause serious injury.

Keep all guards in place at all

times during engine operation.

Wear close-ﬁ tting clothes. Stop the engine and be

sure all fans, belts, pulleys and drives are stopped

before making adjustments, connections, or cleaning

near fans and their components.

Do not allow anything on your person to dangle into

or come in contact with a moving fan, belt, pulley or

drive. Fans can act as vacuums and pull materials

up from below, so avoid that area as well while in

service.

Safe Battery Handling

Prevent Battery Explosions

Battery gas is highly

ﬂ ammable. Battery

explosions can cause severe

injury or death. To help

prevent battery explosions, keep sparks, lighted

matches and open ﬂ ame away from the top of battery.

When checking battery electrolyte level, use a

ﬂ ashlight.

Never check battery charge by contacting the posts

with a metal object. Use a volt-meter or hydrometer.

Frozen batteries may explode if charged. Never

charge a battery that has not been allowed to warm to

at least 16

C (60

F).

Always remove grounded (-) battery clamp ﬁ rst and

replace ground clamp last.

ulfuric acid in battery electrolyte is poisonous and

strong enough to burn skin, eat holes into clothing and

other materials, and cause blindness if splashed into eyes.

To Avoid Hazards:

• Fill batteries only in well-ventilated areas.

• Wear appropriate eye protection and rubber gloves.

• Never use air pressure to clean batteries.

• Wear appropriate ventilation equipment to avoid

inhaling fumes when adding electrolyte.

• Do not spill or drip electrolyte.

• Use correct jump-start procedure if required.

If acid is spilled on skin or in eyes:

1. Flush skin with water.

2. Apply baking soda or lime to

help neutralize acid.

3. Flush eyes with water for

15-30 minutes.

4. Get medical attention

immediately.

If acid is swallowed:

1. DO NOT induce vomiting.

2. Drink large amounts of

water or milk, without

exceeding 2 liters

(2 quarts)

3. Get medical attention immediately

Battery posts, terminals, and related accessories

can contain lead and lead compounds, chemicals

known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

Handle Chemical Products Safely

Direct exposure to hazardous

chemicals can cause serious injury.

Among the potentially hazardous

chemicals that may be used

with Northern Lights

products are lubricants,

coolants, paints and adhesives.

All potentially hazardous chemicals come with a Material

Safety Data Sheet (MSDS). The MSDS provides speciﬁ c

details on chemical products, including physical hazards,

safety procedures and emergency response techniques

OM1276 7/13

Safety Rules (Continued)

Added 1-9-13

Read and understand the MSDS for each chemical before

you start any job that includes it. Follow the procedures

and use appropriate equipment exactly as recommended.

Contact your Northern Lights dealer or Northern Lights

factory for MSDS’s used on Northern Lights products.

Work in Well Ventilated Areas

Exhaust fumes from engines contain carbon monoxide

and can cause sickness or death. Work in well ventilated

areas to avoid prolonged exposure to engine fumes. If it

is necessary to run an engine in an enclosed area, route

the exhaust fumes out of the area with an approved, leak

proof exhaust pipe extension.

Remove Paint Before Welding or Heating

Hazardous fumes can be generated

when paint is heated by welding,

soldering or using a torch. To avoid

potentially toxic fumes and dust,

remove paint before heating.

•

Remove paint a minimum of 100

mm (4 in.) from the

area that will be affected by heat.

•

If paint cannot be removed, wear an approved respirator.

• If you sand or grind paint, use an approved respirator.

• If you use solvent or paint stripper, remove stripper

with soap and water before welding. Remove

solvent or paint stripper containers from the area.

• Allow at least 15 minutes for fumes to disperse

before welding or heating.

Do not use a chlorinated solvent in an area where welding

will occur. Work only in areas that are well ventilated.

Dispose of paint and solvent properly.

Service Cooling System Safely

Opening a pressurized cooling

system can release explosive

ﬂ uids and causing serious burns.

Before opening any pressurized

cooling system, make sure the

engine has been shut off. Do not remove a ﬁ ller cap

unless it

is cool enough to comfortably grip with bare

hands. Slowly loosen cap to relieve pressure before

opening fully.

Avoid High Pressure Fluids

Relieve pressure prior to

disconnecting pressurized lines.

Escaping ﬂ uid under pressure

can penetrate the skin causing

serious injury. Always relieve pressure before

disconnecting hydraulic or other pressurized lines.

Tighten all connections ﬁ rmly before re-applying

pressure.

If searching for leaks, use a piece of cardboard.

Always protect your hands and other body parts from

high-pressure ﬂ uids.

If an accident occurs, see a doctor immediately. Any

high pressure spray injected into the skin must be

removed within a few hours to prevent the risk of

gangrene or other infection.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated

by heating near pressurized ﬂ uid

lines, resulting in severe burns and

bodily injury. Pressurized lines

can rupture when heat goes beyond the immediate

ﬂ ame area. Do not weld, solder or use a torch or

open ﬂ ame near pressurized lines or other ﬂ ammable

ﬂ uids.

Do Not Open High-Pressure Fuel System

Many Northern Lights engines use high-pressure

fuel injection. High-pressure ﬂ uid remaining in fuel

lines can cause serious injury. Do not disconnect or

attempt any repair of fuel lines, sensors, or other

OM1276 7/13

Safety Rules (Continued)

Added 1-9-13

material containing asbestos. Keep all bystanders

away from any area where asbestos dust may be

generated.

Use Proper Lifting Equipment and Techniques

Lifting heavy components incorrectly

can cause severe injury or damage

to machinery. Avoid unbalanced

loads. Do not use lifting eyes. Lift the

generator set using lifting bars inserted

through the lifting holes on the skid.

Follow all recommended removal and installation

procedures in this and associated Northern Lights

manuals.

Use Proper Tools

Makeshift tools and procedures

can create safety hazards.

Always use appropriate tools for

the job.

Use power tools only to loosen threaded parts and

fasteners. For loosening and tightening hardware,

always use the correct sized tools.

Do not use US measurement tools on metric

fasteners, or vice versa. Use only service parts that

meet Northern Lights speciﬁ cations.

Dispose of Waste Properly

Disposing of waste improperly can threaten the

environment and lead to unsafe working conditions.

Potentially harmful waste used in Northern Lights

equipment can include oil, fuel, coolant, ﬁ lters and

batteries.

Use leakproof containers to drain ﬂ uid. Do not

use food or beverage containers that may mislead

someone into drinking from them.

Do not pour waste onto the ground, down a drain or

into any water source.

components between the high-pressure fuel pump

and nozzles on engines with high pressure fuel

systems.

ONLY AUTHORIZED TECHNICIANS

CAN PERFORM REPAIRS ON AN HIGH

PRESSURE FUEL INJECTION SYSTEMS.

Avoid Hot Exhaust

Avoid exposure to and physical

contact with hot exhaust

gases. Exhaust parts and streams can reach high

temperatures during operation, leading to burns or

other serious injury.

Cleaning exhaust ﬁ lters can also lead to exposure to

hot exhaust gas and the injury risk associated with

it. Avoid exposure to and physical contact with hot

exhaust gases when cleaning exhaust ﬁ lters.

During auto or manual/stationary exhaust ﬁ lter

cleaning operations, the engine will run at

elevated temperatures for an extended period of

time. Exhaust parts and streams can reach high

temperatures during operation, leading to burns or

other serious injury.

Avoid Harmful Asbestos Dust

Inhaling asbestos ﬁ bers may cause

lung cancer. Avoid breathing any

dust that may be generated when

handling components containing

asbestos ﬁ bers, including some

gaskets.

The asbestos used in these components is usually

found in a resin or otherwise sealed. Normal

handling of these components is not dangerous,

as long as airborne dust containing asbestos is not

generated.

Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding materials

containing asbestos. When servicing, wear an

approved respirator. A special vacuum cleaner is

recommended to clean asbestos. If this vacuum is

not available, apply a mist of oil or water on the

OM1276 7/13

General Policy

To avoid dangerous or hazardous situations, refrain from

any of the following:

• Removing or bypassing a guard or other safety device

• Placing any part of your body in a position where you

could be caught by moving machinery.

• Cleaning or oiling machinery when in operation.

• Adjusting circuits, chillers, pumps, air handlers, valves,

circuit breakers or fans while in operation.

• Working on piping or high pressure systems.

Lock Out/Tag Out Instructions -

Electrical Equipment

Be sure the equipment’s ON/OFF switch is in the OFF

position and is unplugged from any electrical source before

attempting to perform any type of work on the equipment.

Obtain an electrical plug cap cover with a lockset. Secure

the plug terminal end using the electrical plug lockout cap.

Lock the cap and retain the key.

If the equipment is directly wired into an electrical box with

a shut off switch, obtain a lock pad and/or the appropriate

colored tags and place the lock and tag through the shut

off lever. Retain the key until the repair is completed and

the machine is safe to start. Be certain the shut off lever

is in the OFF position before restarting. NEVER give a

lock out key to unauthorized personnel.

If the equipment is directly wired into an electrical box

without a shut off switch and lock out capability, then a

circuit breaker lock out will be required. Obtain a circuit

lock and tag set. Install the lock onto the circuit breaker

box. Ensure the unit ON/OFF switch is in the OFF position

before restarting.

Lock Out/Tag Out Instructions -

Pneumatic and Hydraulic Equipment

For servicing pneumatic and hydraulic equipment, the

following additional procedures must be implemented,

following completion of lock out/tag out procedures for

the unit to be serviced:

Shut off air, water or supply valves at the equipment to

be serviced.

Check the local bleed-off point for completed release of

pressurized air, water or oil.

If shutting off of air, water or other material cannot be

achieved at the local supply valve, shut off valves further

back in the system and re-check the bleed-off point until

complete shut-off is achieved.

Afﬁ x a DO NOT OPERATE tag to each valve handle that

requires shut off. Each DO NOT OPERATE tag must be

signed and dated by the authorized technician servicing

the equipment.

Lock Out/Tag Out Instructions -

Air Hose Connected Pneumatic Equipment

Equipment connected to the compressed air system

through an air hose with a detachable ﬁ tting must be

shutdown and unplugged. Excess air must be bled prior

to removing the air hose, prior to any maintenance or

repair activities.

Afﬁ x a DO NOT OPERATE tag to the air hose near the

detachable ﬁ tting. Each DO NOT OPERATE tag must be

signed and dated by the authorized technician servicing

the equipment. Check that the equipment cannot be

operated by activating the ON switch.

Stored Energy

Immediately after applying Lock Out or Tag Out devices,

ensure that all potentially hazardous stored or residual

energy is relieved, disconnected, restrained and otherwise

rendered safe.

Veriﬁ cation of Isolation

Verify the machinery or equipment is actually isolated and

de-energized prior to beginning work on a machine or on

equipment that has been locked out.

Restarting Procedures

Follow the procedures below prior to restoring energy:

• Ensure that all machinery or equipment is properly

reassembled. Inspect the machinery or equipment to

verify non-essential items have been removed.

• Ensure that all personnel are safely outside danger

zones. Notify personnel that lock out/tag out devices have

been removed and energy will be reapplied.

• Only authorized personnel may remove lock out/tag out

devices or notices.

Scope

During maintenance, repairs or retooling of a Northern Lights generator set, simply turning the machine off or unplugging

it while it is being worked on does not give enough protection to others who are not performing the maintenance or

repair. Many serious accidents happen when someone thought the machine was turned off, or all of its energy was

safely blocked or released.

Lock Out / Tag Out Procedures

Added 1-9-13

OM1276 7/13

1. Junction Box

2. Turbocharger

3. Exhaust Manifold

4. Low Water Flow Switch

5. Thermostat Housing

6. Low Coolant Level

Switch/ Gauge (optional)

7. Coolant Fill

8. Expansion Tank

9. Heat Exchanger

10. Belt Guard

11. Alternator

12. Optional Hydrolastic Mount

13. Lube Oil Filter

Component Locations

Figures 1 & 2: M1276

14. Oil Fill

15. Lube Oil Dipstick

16. Oil Cooler

17. Fuel/ Water Separator

18. Intake Manifold

19. Air Cleaner

20. Engine Control Unit

21. Starter

22. Raw Water Pump

23. Heat Exchanger Zinc

1516

OM1276 7/13

Northern Lights Control Panels

Figure 3: Series 3B Generator Control Panel

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature

during the starting process.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.

NOTE: Excessive cranking of marine sets equipped

with water lift mufﬂ er systems can cause engine

damage.

After the engine starts, release the switch and it will

return to RUN position. To stop the engine, hold

the switch in the STOP position.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in

the engine lubricating system. If the pressure drops

below 15 PSI at a speed higher than idling, stop the

engine and investigate.

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of

the cooling water. If the gauge registers over 200°

or drops below 140°, stop the engine and investi-

gate.

5. HOUR METER

Keeps track of the engine running time.

6. DC VOLTMETER

When the engine is running, it indicates the voltage

output of the alternator.

OM1276 7/13

Figure 4: Series 4 B Generator Control Panel

7. AC VOLTMETER

The voltmeter shows the generator output

voltage, phase to phase. If the voltage

ﬂ uctuates greatly from the normal reading, shut

down the unit and investigate.

8. FREQUENCY METER

Indicates engine speed. The correct reading for

1800 and 1200 RPM sets is 60 Hz. For 1500 RPM

sets, it is 50 Hz. If meter does not

indicate correct hertz, stop and investigate.

9. AMMETER SELECTOR SWITCH

The ammeter switch is used for checking each

phase for load condition. Leave it in the ON posi-

tion while the engine is running.

10. AC AMMETER

The ammeter indicates the phase load. Check for

load unbalance. If the unbalance is greater than

30%, have an electrician balance the load properly.

This will ensure longer generator life and better

economy.

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature

during the starting process.

2. ENGINE CONTROL SWITCH

The control switch starts and stops the engine.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in

the engine lubricating system. If the pressure drops

below 15 PSI at a speed higher than idling, stop the

engine and investigate.

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of

the cooling water. If the gauge registers over 200°

or drops below 140°, stop the engine and investi-

gate.

5. HOUR METER

Keeps track of the engine running time.

6. DC VOLTMETER

When the engine is running, it indicates the voltage

output of the alternator.

Northern Lights Control Panel

OM1276 7/13

Operating Procedures

BEFORE STARTING

1. Check the water level by removing the pressure

cap from the expansion tank. In order to give the

cooling water room to expand, the level should be

about 1 3/4 in. (4-5 cm) below the ﬁ ller cap sealing

surface when the engine is cold. When ﬁ lling with

coolant, the venting cock on top of the turbocharger

should be opened to ensure that no air pockets form

in the cooling system (see Service Point #14).

CAUTION: Use protective clothing and open

the ﬁ ller cap carefully when the engine is warm

to prevent burns.

2. Check the oil level in the crankcase with the dipstick.

The oil level should be between the “wafﬂ ed area”

and the “oo”. Never allow the level to go below

the “oo”. Always add the same viscosity of oil as is

already in the crankcase (see Service Point #1).

3. Check the fuel tank level and open any fuel valves.

4. Disengage clutch, if equipped.

5. Close the seacock, check and clean the strainer and

reopen the seacock.

6. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON

while the engine is running. If the switch is turned

OFF while the engine is running, the battery charging

regulator could be ruined.

Starting

1. While holding the Shutdown Bypass switch in the

ON position, push the Engine Control switch to the

START position.

2. As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3. If the engine fails to start the ﬁ rst time, be sure the

starter has stopped before re-engaging.

NOTE: Avoid prolonged periods of engine idling or

sustained running time at maximum load during the

ﬁ rst 20 hours. Stop the engine if idling longer than 5

minutes. The engine should have an oil pressure of

at least 138 kPa (20 PSI) at low idle.

Operating

1. Check Gauges Often: Oil pressure must be above

29 PSI (if not above 15 PSI within 5 seconds of

starting, the engine should be stopped and the prob-

lem should be explored). Normal oil pressure is 45

+ 15 PSI at rated load speed (1800 to 2500 RPM).

Coolant temperature should be 82

- 94

C (180

202

F) for normal operating temperature. The D.C.

voltmeter should read between 13 and 14 volts (26-

28 volts, 24 volt systems).

2. Check AC voltage and frequency meters (Series 4

Panel). If gauges deviate from normal levels, shut

down the set and investigate.

3. Check belt for good alignment.

4. Let the unit run unloaded for a three to ﬁ ve minute

warm-up period before applying load.

5. Do not add full electrical load until engine is at

maximum operating temperature.

Shutdown

1. Turn the Engine Control Switch to the OFF position.

2. Close the sea cock and fuel valves, and put the bat-

tery switch in the OFF position if the unit will be off

for an extended period.

NOTE: Do not turn the battery switch to OFF while

the engine is running.

SHUTDOWNS AND ALARMS

1. Your unit is ﬁ tted with a system to protect it from high

water temperature or low oil pressure.

a. Generator sets have shutdown systems to stop the

engine. They have no warning horns.

b. Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your warning or shutdown

system to the exclusion of careful gauge monitoring.

Watching your gauges can prevent damage to the unit

and dangerous power losses.

2. Do the following when your shutdown system is

activated:

a. Check the temperature gauge. If the temperature is

above 205°F (97°C), shut off the engine immediately.

b. Use the Trouble Shooting Guide on pages 23- 27

to isolate the cause of the overheat.

OM1276 7/13

Operating Procedures

SHUTDOWNS AND ALARMS continued

CAUTION: Do not remove the water ﬁ ll cap of

an overheated engine. Escaping high

temperature steam can cause severe burns.

Allow the engine to cool and then remove the

cap slowly, using protective clothing.

c. Make repairs and restart after the temperature

gauge registers below 180°F (83°C).

d. Watch the temperature gauge regularly and turn

off the unit if the temperature rises above 200°F

(94°C). Repeat the troubleshooting process.

3. If the shutdown is activated and the temperature gauge

shows temperature within normal temperature range:

a. Check the engine crankcase oil level.

If the oil level is low, ﬁ ll with recommended lubricating

oil and restart. Watch the oil pressure gauge carefully

and shut off the engine if it does not show a normal

reading after a few seconds of operation.

c. If the oil level was normal, DO NOT restart the

engine. Call your Northern Lights or Lugger

dealer for assistance.

BREAK-IN PERIOD

1. The ﬁ rst 100 hours on a new or reconditioned engine

are critical to its life and performance.

2. Operate the engine under various conditions,

particularly heavy loads with minimal idling, to help

seat engine components properly.

3. Constantly check the engine temperature and oil pres-

sure gauges.

4. Oil consumption is greater during break-in as piston

rings and cylinder liners take time to seat.

5. Break-In Oil Changes: Change engine oil and ﬁ lter

at 50 hours. Change oil and ﬁ lter again at 100 hours,

then at every 250 hours. (See Gear Owner's Manual

for break-in oil change procedures. Consult Lubricants

Section for oil recommendation).

SP5. Belt Tension and Wear

1. Automatic belt tensioners on belt drive systems

cannot be repaired - they have to be replaced as a

whole assembly. If the tensioner spring tension

does not meet the speciﬁ cation then it would need

to be replaced.

The cast stops "A" and "B" on the ﬁ gure below

show where the limit of the arm movement of the

belt tensioner is designed to operate within.

(Assuming correct belt length and geometry have

been used.)

Inspect the cast stops "A" and "B" to see if the

tensioner stop on the swing arm (A) is hitting the

ﬁ xed stop (B). If it is check the mounting brackets

of the alternator, belt tensioner, idler pulley, etc...,

and the belt length. Replace belt if needed.

Reproduced by permission of Deere & Company, c2006. Deere & Company. All

rights reserved. RG8742

A- Swing Arm Cast Stops

B- Fixed Cast Stops

Revised 1/9/13

OM1276 7/13

Service Schedule Chart

The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your marine engine

or generator set. More detailed coverage of each Service Point (SP) is listed on the page

DAILY:

SP1 Check oil level in engine

SP8 Check primary fuel ﬁ lter

SP15 Check coolant level

AFTER FIRST 50 HOURS:

SP2 Change engine oil

SP3 Change lube oil ﬁ lter

EVERY 50 HOURS:

SP21 Check electrolyte in batteries

AFTER FIRST 100 HOURS/ EVERY TWO WEEKS

SP2 Change engine oil after ﬁ rst 100 hrs., then check every 2 wks.

SP3 Change oil ﬁ lter after ﬁ rst 100 hrs., then check every 2 wks.

SP7 Check crankshaft vibration damper

SP4 Check air cleaner valve & restriction indicator gauge

EVERY 200 HOURS:

SP4 Replace air cleaner

SP2 Change engine oil & ﬁ lters (fuel ﬁ lter/water bowl)

SP9 Change primary ﬁ lter element (Racor)

SP10 Change secondary fuel ﬁ lter

SP14 Check turbocharger boost pressure

SP22 Check the state of the charge of the batteries

SP25 Check engine mounts

SP26 Clean crankcase vent tube

SP27 Check air intake hoses

SP30 Check engine speeds

EVERY 500 HOURS:

SP5 Check belt condition

SP16 Check cooling system

SP17 Check and clean heat exchanger

SP18 Check and clean gear oil cooler

SP20 Change impeller in raw water pump

SP31 Adjust variable speed (droop)

EVERY 2000 HOURS:

SP7 Check crankshaft vibration damper

SP6 Check & adjust valve clearance

SP16 Check and ﬂ ush cooling system

SP23 Test thermostats

1) Change the oil & ﬁ lter before the ﬁ rst 100 hours of operation at engine break-in.

2) Perform all maintenance once a year even if hour level has not been reached.

3) Consult manufacturer's maintenance schedule, note on chart.

4) Whenever necessary.

5) Operate engine at rated speed with 50-70% load for 30 min. at least.

SERVICE 50 100 200 500 2000

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

ENGINE:

SP1 13 Check oil level •

SP2 13 Change engine oil 1) 2) 8) • •

SP3 13 Change lube oil ﬁ lters 1) 2) 8) • •

SP4 13 Check air cleaner valve 2) 4) 6)8) • •

SP5 10 Check belt condition 2) •

SP6 14 Check valve clearances 2) •

SP7 18 Check crankshaft vibration damper 7) •

SP25 18 Check engine mounts •

 SP27 19 Check air intake hoses •

SP30 9 Check engine speeds •

FUEL SYSTEM:

SP8 16 Check primary ﬁ lter (Racor) 3) • •

SP9 16 Change primary ﬁ lter element (Racor) 3) 4) •

SP10 16 Change secondary fuel ﬁ lter 2) 4) •

SP11 15 Check injectors 8) 9)



TURBOCHARGER:

SP13 19

Check air, oil & cooling water lines for leakage

•

SP14 19 Check boost pressure •

COOLING SYSTEM:

SP15 21 Check coolant level • •

SP16 21 Check and ﬂ ush cooling system 2) • •

SP17 21 Check and clean heat exchanger 2) •

SP18 Check and clean gear oil cooler 2)  •

SP19 21 Check zinc electrodes 2) 4)  •

SP20 22 Change impeller in raw water pump 2) 4) •

SP23 18 Test thermostats •

ELECTRICAL SYSTEM:

SP21 23 Check electrolyte level in batteries 2) 4) • •

SP22 23 Check condition of batteries with hydrometer 2) •

6) Replace air cleaner element when restriction indicator shows vacuum of

625 mm (25 in.) H

7) Replace damper every 4500 hours or after 60 months.

8) At 2500 hrs. an electronic injector preload adjustment must be made.

9) Check at 5000 hours.

Revised 7-10-13

OM1276 7/13

HOURS/DATE

Service Record Notes

SERVICE OPERATION

OM1276 7/13

LUBRICATION

Break-in oil

1. Use one of the following during the ﬁ rst 100 hours

of operation:

a. John Deere Engine Break-In Oil

b. API Service CC, CD, & CE oil

c. ACEA Speciﬁ cation E1, E2

2. Do not use John Deere PLUS-50 oil or engine oils

meeting API CG-4, API CF-4, API CF-2, API CI-4,

API CI-4 Plus, API CH-4, ACEA E3, E4, E5, E6, &

E7 performance levels during the ﬁ rst 100 hours of

operation of a new or rebuilt engine. These oils will

not allow the engine to break-in properly.

Lubrication - General

1. Use only clean, high quality lubricants stored in

clean containers in a protected area.

2. These oils are acceptable after the ﬁ rst 100 hours:

a. ACEA Oil Sequence E4, E5, E6, or E7.

b. API Service Category CI-4, CH-4, CI-4 Plus.

c. ACEA Oil Sequence E3 multi-viscosity oil.

(Multi-viscocity oils are preferred.)

3. Use the proper weight oil for your average operation

temperature.

4. Some increase in oil consumption may be expected

when SAE 5W and SAE 5-20W oils are used. Check

oil level frequently.

5. Never put additives or ﬂ ushing oil in crankcase.

6. If using diesel fuel with sulfur content of 0.05% to

0.5%, service interval for oil changes increases to

every 150 hours.

SP1. CHECK ENGINE OIL LEVEL

1. Check the oil level in the crankcase, with the oil

dipstick, daily.

2. The oil level must be between the “Wafﬂ ed area” and

the “oo”. Never allow the level to go below the “oo”.

3. Always add the same viscosity of oil as is already in

the crankcase.

SP2. OIL CHANGES

1. Using the oil recommended above, change the engine

oil and ﬁ lter after the ﬁ rst 50 hours of operation, the ﬁ rst

100 hours and every 250 hours thereafter.

2. During intermittent cold weather operation, change oil

every 100 hours or six weeks, whichever comes ﬁ rst.

3. Change oil at any seasonal change in temperature when

a new viscosity of oil is required.

a. Run engine about 5 minutes to warm up oil then shut

off engine.

b. Remove plug from outlet in base frame. Screw in

owner-supplied drain hose.

c. Open valve at oil pan outlet. After warm oil has been

drained into suitable container, close valve, remove

drain hose and replace plug in base frame outlet.

d. Reﬁ ll engine with recommended oil.

4. Engine Lube Oil Capacity:

42.3 qts. (40.0 L)

SP3. CHANGING OIL FILTER

1. Change the lube oil ﬁ lter every 200 hours.

2. Use a ﬁ lter wrench to remove old ﬁ lter. Dispose of ﬁ lter

in approved manner.

3. Make sure the gasket from the old ﬁ lter is removed and

discarded.

4. Lubricate the rubber gasket on the new ﬁ lter and screw it

on nipple until gasket meet the sealing surface.

Using hands only, no wrench, tighten ﬁ lter one-half turn

farther. Overtightening can do damage to ﬁ lter housing.

6. Install oil pan drain plug with a new o-ring, torque to:

1-1/4" plug torque....................46 N•m (34 ft/lbs.)

1-1/2" plug torque....................64 N•m (47 ft/lbs.)

7. Fill engine with recommended oil. Start engine and

check for leakage. Stop engine and check oil level. Add

additional oil if necessary.

SP4. AIR CLEANER

1. Inspect air cleaner every 100 hours. Replace ﬁ lter every

250 hours, or yearly, whichever comes ﬁ rst.

2. Clean the rubber tube at the cleaner. Loosen the hose

clamp and the attaching strip for the cleaner.

3. Make sure the rubber tube is in good condition and that

new ﬁ lter is absolutely clean and installed properly.

4. Start the engine and check for leaks.

NOTE: Make absolutely sure no impurities enter the

engine while changing the element. Do not run the engine

with the air cleaner removed.

Air Single Multi

Temperature Viscosity Viscosity

Above 32°F

(0°C)

SAE-30W SAE15-40W

-10°F to 32°F

(-23°C to 0°C)

SAE-10W SAE10-30W

Below -10°F

(-23°C)

SAE-5W SAE5-20W

Servicing

OM1276 7/13

SP6. VALVE CLEARANCES

After the ﬁ rst 2000 hours of operation it is required

that the intake and exhaust valve clearance and

electronic unit injector preload needs to be adjusted

by your certiﬁ ed Northern Lights dealer.

1. Remove the rocker arm cover.

2. Then remove the plug from the cylinder block and

install a JDG820 Flywheel turning tool (Fig. 5-B).

Servicing

Reproduced by permission of Deere & Company, c2006. Deere

Figure 5

Note: First the timing pin must be installed in the slot

of the camshaft, then by carefully rocking the ﬂ ywheel

back and forth install the second timing pin.

3. Rotate the engine ﬂ ywheel in the running

direction (counterclockwise viewed from the rear)

until the timing pin (Fig. 6-A) engages into the

single timing slot (Fig. 7-D) camshaft. By looking

through the camshaft timing pin bore while

rotating the engine, the proper timing slot can be

found. The double timing slot (Fig. 7-E) will be

at 11:00 (from the rear of the engine) when the

pin is installed in the slot (Fig.7-D). This will

ensure that the engine is locked at Top Dead

Center of the No. 1 cylinder's compression stroke.

The No. 1 cylinder's intake and exhaust rocker

arms should be loose.

4. Take out the plug from the crankshaft timing hole

below the oil cooler and ﬁ lter housing assembly.

Reproduced by permission of Deere & Company, c2006. Deere

Figure 6

Note: Do Not insert the timing pin all the way into the

cylinder block crankshaft timing hole when rotating the engine

ﬂ ywheel until the double slot on the camshaft timing lobe is

approximately at 11 o'clock as viewed from the rear of the

engine (Fig. 7). This will prevent the crankshaft

counterweight from bending the timing pin.

5. Move the engine ﬂ ywheel slightly back and forth with a

turning tool until a second timing pin (JDG971) can be

installed in the slot in the crankshaft (Fig. 5-C). This is

to ensure that the camshaft and crankshaft are in time;

properly in sync. If the timing pin does not go into the

crankshaft timing slot, the crankshaft is not properly timed

with the camshaft. The crankshaft must be timed to the

camshaft. If it is not, leave the timing pin in and remove

the gear access cover from the timing gear cover. Loosen

the camshaft gear retainer capscrews and rotate the crank-

shaft with a ﬂ ywheel turning tool (JDG820) and install a

second timing pin (JDG971) in the crankshaft timing slot.

Reproduced by

permission of Deere &

Company, c2006.

Deere & Company.

RG11165

Figure 7

OM1276 7/13

Servicing

6. Check and adjust, if need be, the valve stem-to-bridge

clearance (also called "lash") on intake valves numbers 1,

2, and 4, and exhaust valves numbers 1,3, and 5. (Shaded

on Fig. 8).

Adjust the preload on electronic unit injectors

numbers 3, 5, and 6. (Shaded on Fig. 8).

Adjust the valve clearance using a JDG1333 Feeler Gauge

Set or a 1/4 inch (6 mm) wide automotive ignition feeler

gauge (point type). Install the gauge at the joint between

the valve bridge and valve stem tip (Fig. 9-B) near the

exhaust side of the engine. Loosen the lock nuts and set

the clearance with the adjusting screw. Tighten the lock

nut to the below speciﬁ ed torque while holding the

adjusting screw stationary.

Valve Stem-to-Bridge Clearance (Cold Engine):

Intake Valve clearance...................0.58 + 0.05 mm (0.023 + 0.002 in.)

Exhaust Valve clearance................1.08 + 0.05 mm (0.043 + 0.002 in.)

7. Tighten the intake and exhaust valve adjusting screw lock

nuts to below speciﬁ cation.

Intake & Exhaust Valve Adjusting Screw Lock Nuts Torque:

50 N•m (37 ft-lbs.)

RG8773 Figure 8

RG8232 Figure 9

Electronic Unit Injector Preload Adjustment

8. For preload adjustment, when the crankshaft is timed

to the camshaft, loosen lock nut (Fig. 10-A) and

rocker arm injector adjusting screws for cylinders 3,

5, and 6 to relieve the tension.

9. Slowly tighten the adjusting screw until the rocker

arm roller contacts the camshaft lobe at a 0.0 clear-

ance.

10. Then tighten the adjusting screw an additional 1/2

turn (180

) to preload injector. Tighten the adjusting

screw lock nut to below speciﬁ cation while holding

the adjusting screw from moving.

Electronic Unit Inj. Adjusting Screw Lock Nut

Torque.....65N•m (48 ft/lb.)

11. Remove both timing lock pins, rotate crankshaft one

full revolution (360

) and pin the crankshaft only.

The engine will now be locked at No. 6 Top Dead

Center.

12. Set injector preload on the cylinders Nos. 1, 2, and 4.

13. Install the plug in the timing pin hole in the block

and tighten to below speciﬁ cation.

Timing Pin Plug in Cylinder Block Torque .........33 N•m

(24 ft/lb.).

Reproduced by permission of Deere & Company, c2006. Deere

Figure 10

Page is loading ...

Nothern Lights M1276A1 User manual

Brand: Nothern Lights

Model: M1276A1

Category: Engine

Type: User manual

This manual is also suitable for

M1276A2

Download PDF

report

Nothern Lights M1276A1 User manual

This manual is also suitable for

Nothern Lights M1276A1 User manual

Related papers

Other documents